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Lunatic

Guitar Kit Assembly Instructions

www.byoguitar.com

http://www.byoguitar.com/

Introduction

Lunatic Intro- 1 -

Warning

These instructions assume that you are familiar with the safe operation and use of woodworking

machinery and woodworking tools, and understand the techniques used to assemble this project. If you do

not qualify for both of these criteria, STOP building this project for your own safety. Read and understand

the owner’s manual for the machinery you intend to use, take a woodworking class or visit your local

library for more information. Woodworking machinery and tools are inherently dangerous because they

use sharp edges that can and will cause serious personal injury including amputation and death. Do not

underestimate the ability of these tools and machinery to cause injury. Never operate any tool without all

guards in place and always wear approved safety glasses. For your own safety, please heed this warning.

Warning

Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses are

not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American

National Standards Institute (ANSI). Because there are various ways to cut and join wood, you can make

substitutions for the methods stated in this manual. We try to suggest the easiest methods possible.

However, only you know your skills with each piece of machinery. Never compromise your safety by using

a cutting method with which you are not comfortable. Instead, find an alternative approach that will yield

the same result.

Warning

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains

chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Some examples of these chemicals are:

Lead from lead-based paints.

Crystalline silica from bricks, cement, and other masonry products.

Arsenic and chromium from chemically treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your

exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment,

such as those dust masks that are specially designed to filter out microscopic particles.

California requires the following notice:

Introduction

Lunatic Intro- 2 -

Contents Contents .................................................................................................................................................... - 2 -

1 Introduction ...................................................................................................................................... - 4 -

1.1 Material Check List .................................................................................................................... - 5 -

1.2 Additional tools/materials required: ........................................................................................ - 7 -

2 Mockup and Fit Check ....................................................................................................................... - 1 -

2.1 Checking the Mounting Holes in the Neck ................................................................................ - 1 -

2.1.1 Drilling Mounting Holes in the Neck (Fig 2.1) ................................................................... - 1 -

2.1.2 Mount the Neck on the Body ............................................................................................ - 2 -

2.2 The Bridge ................................................................................................................................. - 2 -

2.3 Fit check & Alignment of the Pickup ......................................................................................... - 2 -

2.4 Check Tremolo Claw Alignment and Fit Check (item #5 on material list) ................................. - 3 -

2.5 Fit check of the back covers (Fig 2.5.1) ..................................................................................... - 3 -

2.5.1 Tremolo cover: .................................................................................................................. - 3 -

2.5.2 Volume Cover: ................................................................................................................... - 3 -

2.5.3 Truss Rod Adjustment Access Cover ................................................................................. - 3 -

2.6 Check Strap Pins ........................................................................................................................ - 3 -

2.7 Check Tuner Alignment ............................................................................................................. - 4 -

2.8 Check Output Jack ..................................................................................................................... - 4 -

2.9 Mockup and Fit Check complete! ............................................................................................. - 4 -

3 Finish ................................................................................................................................................. - 1 -

3.1 Finish Application Steps ...................................................................................................... - 2 -

3.1.1 Solid Color finish: .......................................................................................................... - 2 -

3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish: ....................................... - 2 -

3.1.3 Penetrating Stain or water based dye finish: .......................................................... - 2 -

3.2 Explanation of Sequence Steps: .......................................................................................... - 2 -

3.2.1 Sanding the Body and Neck ......................................................................................... - 2 -

3.2.2 Appling Grain Filler ...................................................................................................... - 3 -

3.2.3 Applying Sanding Sealer .............................................................................................. - 3 -

3.2.4 Solid Color Primer ......................................................................................................... - 3 -

Introduction

Lunatic Intro- 3 -

3.2.5 Burst and Translucent finishes .................................................................................. - 4 -

3.2.6 Clear Top coats .............................................................................................................. - 4 -

3.2.7 Buff finish ........................................................................................................................ - 4 -

4 Assembly ........................................................................................................................................... - 1 -

4.1 Installing the tuners .................................................................................................................. - 1 -

4.2 Neck Installation ....................................................................................................................... - 1 -

4.3 Installing the Strap Pins ............................................................................................................. - 1 -

4.4 Installing the Floyd Rose Tremolo ............................................................................................. - 2 -

4.5 Install the Pickup ....................................................................................................................... - 2 -

4.6 Prep the for the Output Jack, Volume control & wiring ........................................................... - 3 -

4.6.1 Wire color coding/prep ..................................................................................................... - 3 -

4.6.2 Soldering the Components ............................................................................................... - 4 -

4.6.3 Final wiring – Volume Control ........................................................................................... - 4 -

4.7 Install the Strings....................................................................................................................... - 4 -

4.8 Tremolo Claw Adjustment ........................................................................................................ - 6 -

5 Initial setup ....................................................................................................................................... - 1 -

5.1 Adjust the Guitar Neck: Truss Rod ............................................................................................ - 2 -

5.1.1 Check the Neck .................................................................................................................. - 2 -

5.1.2 Adjusting the Truss Rod .................................................................................................... - 2 -

5.2 String Lubrication ...................................................................................................................... - 2 -

5.3 Re-check the Bridge Alignment ................................................................................................. - 3 -

5.4 Adjusting the Action (string height) .......................................................................................... - 3 -

5.5 Pickup Height (Figure 5.4) ......................................................................................................... - 4 -

5.6 Intonation (Figure 5.6) ............................................................................................................. - 4 -

5.7 …Other Hints ............................................................................................................................. - 5 -

Introduction

Lunatic Intro- 4 -

Fig 1 Major Components in Your Lunatic Guitar Kit

1 Introduction Thank you for purchasing a BYOGuitar.com guitar kit. This

kit includes everything you need to build a complete custom

guitar. In addition to the construction of your guitar, you

will need to consider the finish – natural, solid color and

possibly a design that will make your guitar unique. We

suggest you do some research to determine your finish preferences. Procuring the required finishing

materials, especially if they have to be ordered, will allow expedite your guitar project.

We carry a full line of finishing products to give you the beautiful finish you are looking for, whether a

clear natural finish or a bold, colorful finish. We also carry an instructional DVD made by Behlen that will

give you step by step instructions to help you achieve the look you want for your custom guitar.

These instructions assume you are familiar with the anatomy of a guitar. Refer to Figure 1 for many of

the terms used in the assembly of your guitar.

TIP: Get some finishing ideas by

visiting BYOGuitar.com and BYO Guitar on Facebook

Introduction

Lunatic Intro- 5 -

1.1 Material Check List In preparation for the building of your guitar, all required material should be checked both for type and

quantity. Use the following check list to ensure all piece parts are included. If you customized your

order (ex. different tuners), ensure that these parts are accounted for. Please contact BYOGuitar if there

are any discrepancies.

Lunatic Material List

Item Component Quantity Description

1

1 Lunatic Body

1 Lunatic Neck

Miscellaneous materials (see below)

BYO Lunatic Guitar Kit

2

Volume pot

Knob

Wire: Audio Controls

Audio Controls

3

12 screws 3/8”

Mounting screws

Audio Jack &

Back Plates

4

1

2 mounting inserts/screws

Lunatic Bridge/Tremblock

TIP: use small interior packing

box to inventory and organize piece parts

Introduction

Lunatic Intro- 6 -

5

Trem Claw

Springs, 3

Screws, 1 ½”, 2

Tremolo parts

6

Arm Wammy bar

7

Mounting plate, 1

Plastic spacer,1

4 screws, 13/4”

Neck mounting

materials

8

6 Tuning Pegs

6 Washers

6 Nuts

6 screws, 3/8”

Tuning Peg

materials

9

Jack

Mounting screws 5/8”, 2

Output Jack

10

2 Holders

2 plastic washers

2 screws, 1”

Strap Holder

materials

11

Pickup

4 screws, ¾”

Pickups material

12

Tremolo claw cover, 1

Volume, 1

Truss rod, 1

Body (back)

Access & truss

rod Covers

Introduction

Lunatic Intro- 7 -

13

6 strings Strings

14

Output Cable

3 Allen wrenches

Other

1.2 Additional tools/materials required: Drill & drill bits #1 & #2 Phillips

screwdriver

Soldering iron/solder

Masking/painters tape Finishing/painting material Sand paper 220 & 320 grit

Guitar strap Soap or candle Feeler gauge

ruler Wood glue

Introduction

Lunatic Intro- 8 -

The remainder of the assembly instructions is divided into four sections:

Section 2 – Mockup & Fit check: in this section, all components will be checked for proper

alignment and ensure that all holes have been drilled.

Section 3 – Finishing the Body and Neck: after fit check, the components are removed from the

neck & body to allow the selected finish to be applied. This will allow you to customize your guitars’

color(s). As the finishing will likely require several coats with sanding between each coat, ensure that

the finish is completely dry.

Section 4 – Construction: the final assembly is the next step - once the finish has been applied

and completely dried. In this section, all of the components are installed, internal wiring connected and

strings attached – your guitar will ready to go!

Section 5 – Setup: in this section, adjustments are made to your guitar such as the height of the

pickups.

Again, we thank you for your purchase of a BYO Guitar and we look forward to seeing pictures of your

unique guitar! We also look forward to providing you with the guitar for your next project from our

Custom Shop where you can select the wood for the body and neck as well as customizing all of the

other components.

Let us know if your music, school, church or scouting organization would like to undertake a group

project – BYO Guitar can supply multiple kits or custom guitars.

Examples of Our Custom Shop Products

Section 2 – Mockup and Fit Check

Lunatic Section 2 - 1 -

Section 2 Contents

2 Mockup and Fit Check ....................................................................................................................... - 1 -

2.1 Checking the Mounting Holes in the Neck ................................................................................ - 1 -

2.1.1 Drilling Mounting Holes in the Neck (Fig 2.1) ................................................................... - 1 -

2.1.2 Mount the Neck on the Body ............................................................................................ - 2 -

2.2 The Bridge ................................................................................................................................. - 2 -

2.3 Fit check & Alignment of the Pickup ......................................................................................... - 2 -

2.4 Check Tremolo Claw Alignment and Fit Check (item #5 on material list) ................................. - 3 -

2.5 Fit check of the back covers (Fig 2.5.1) ..................................................................................... - 3 -

2.5.1 Tremolo cover: .................................................................................................................. - 3 -

2.5.2 Volume Cover: ................................................................................................................... - 3 -

2.5.3 Truss Rod Adjustment Access Cover ................................................................................. - 3 -

2.6 Check Strap Pins ........................................................................................................................ - 3 -

2.7 Check Tuner Alignment ............................................................................................................. - 4 -

2.8 Check Output Jack ..................................................................................................................... - 4 -

2.9 Mockup and Fit Check complete! ............................................................................................. - 4 -

2 Mockup and Fit Check The following steps will ensure that the base, neck, tuners,

pickup, etc. are properly aligned and that all screw holes

have been drilled.

2.1 Checking the Mounting Holes in the

Neck 1. Check the neck for pre-drilled (4) mounting holes.

2. Skip to 2.1.2 if the holes are pre-drilled.

2.1.1 Drilling Mounting Holes in the Neck (Fig 2.1)

1. Place the neck in the pocket (…you should be able to

fit the neck in the neck pocket by hand).

a. Make sure the neck is aligned properly with

the pickup pocket.

b. Carefully clamp the neck in place – frets

damage easily.

Figure 2.1 Body Pocket Locations



c. Using the 3/32 drill bit, place the bit in the hole through the

body and tap it a few times to make a mark on the neck.

d. Remove the neck from the body.

2. Determine the neck mounting hole depth.

a. Place one of the neck mounting screws with mounting

plate & plastic spacer (item #7 on material list) through the

body into the neck pocket.

b. Measure the amount of the mounting screw that extends

up into the neck pocket, and mark your drill bit.

c. Double check the depth by holding the marked drill bit to the side of the neck and be

certain the drill won’t go through the fingerboard.

3. Drill the holes in the neck with a 1/8” drill bit. Make sure you don’t

drill through the fingerboard!

2.1.2 Mount the Neck on the Body

Temporarily attach the neck. Use caution, the last thing you want to do is

snap the screw off in the hole!

1. Insert the neck into the neck pocket aligning the mounting holes in

the neck and body;

2. Using the neck plate & plastic spacer (item #7 on material list), fasten the Neck & Body with 4 - 1 3/8” screws - do not over tighten.

2.2 The Bridge Mounting the Bridge assembly (item 4 on material list) utilizes two inserts in

the Bridge Pocket (Fig 2.1).

1. Remove the adjustment bolts from the inserts;

2. Using a small block of wood, gently tap the inserts into the Body -

being cautious that the block does not contact the Body as it might leave small dents that will

require sanding when you finish your guitar. When

finishing the Body (Section 3), be careful not to allow

finish material into the insert holes.

2.3 Fit check & Alignment of the Pickup Fit check & align the pickup by:

1. From the front of the Body, carefully run the Pickup

shielded pickup wire through the tunnel between the

Pickup pocket and the Volume control pocket (Fig.

2.3), ensuring that the pickup is flush against the Body;

TIP…a

piece of masking tape around the drill bit works

great as a depth indicator.

Figure 2.3 Body Tunnels

TIP…to

reduce the chances of the wood splitting, use soap or wax on screw

threads

TIP… soap

or wax on the inserts will help



2. Align and center the pickup over the pocket;

3. Mark the 4 holes and drill starter holes with 1/16 drill bit.

The wiring of the pickup and other components will be covered in Section 4.

2.4 Check Tremolo Claw Alignment and

Fit Check (item #5 on material list) Place the Tremolo claw in the back pocket of the Body

(Fig 2.4) ensuring the claw is centered in the pocket.

1. In order to make the assembly process easier,

pre-tin (solder) the attachment point for the claw

ground wire (raised tab in the center of the claw);

2. Using the claw as a template, mark the hole

positions and pre-drill 2 holes;

3. Start the mounting screws approximately ½” into

the Body – ensure they are centered (Figure 2.4);

2.5 Fit check of the back covers (Fig 2.5.1)

2.5.1 Tremolo cover:

1. Carefully align and center the rectangular cover over

the pocket, ensuring that there is room for the round

cover directly below (item 12 in material list);

2. Mark the holes and drill starter holes with 1/16 drill

bit.

2.5.2 Volume Cover:

1. Place cover over the round pocket, with the counter

sunk mounting holes facing up (item 12 in material

list);

2. Mark and drill starter holes with 1/16 drill bit.

2.5.3 Truss Rod Adjustment Access Cover

1. Center the cover over the Truss Rod adjustment

pocket (Figure 2.5.3);

2. Mark and drill starter holes with 1/16 drill bit – use

caution as the headstock is relatively thin.

2.6 Check Strap Pins 1. Check for pre-drilled holes for the Strap Pins (item 10

on the material list), reference Figure 1.0.

Figure 2.4 Tremolo claw Alignment

Figure 2.5.1 Back Body Cover Alignment

Figure 2.5.3 Truss Rod Cover



2. If the holes are pre-drilled, skip to 2.7.

a. Mark the rear Strap Pin hole so that it is centered on the Neck/Bridge and the forward

Pin on the most forward point on the top of the Body (see Figure 1.0).

b. Drill starter holes with a 1/16 drill bit.

2.7 Check Tuner Alignment Each tuner consists of the tuner, washer, and a threaded

bushing (item #8 on material list).

1. Insert tuners, 6 each, into the Neck Headstock.

Ensure that the Tuner shafts are perpendicular to the

Headstock (Fig. 2.7);

2. Check alignment of set screw holes and tuner base;

3. If alignment is incorrect or holes are not drilled, mark

hole locations and drill starter holes with 1/16 “ drill

bit being careful not to drill through the headstock.

2.8 Check Output Jack 1. Align the Output Jack (# 9 on the material list) in the hole in the back of the Body (Figure 1).

2. Mark and drill the 2 mounting holes with 1/16” drill.

2.9 Mockup and Fit Check complete! Carefully disassemble the Mockup and move on to the next step: applying the finish to your guitar!

Figure 2.7 Tuner Alignment

Section 3 - Finishing Your Guitar


Section 3 Contents

3 Finish ................................................................................................................................................. - 1 -

3.1 Finish Application Steps ............................................................................................................ - 2 -

3.1.1 Solid Color finish: .............................................................................................................. - 2 -

3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish:................................................... - 2 -

3.1.3 Penetrating Stain or water based dye finish: .................................................................... - 2 -

3.2 Explanation of Sequence Steps: ................................................................................................ - 2 -

3.2.1 Sanding the Body and Neck .............................................................................................. - 2 -

3.2.2 Appling Grain Filler ............................................................................................................ - 3 -

3.2.3 Applying Sanding Sealer .................................................................................................... - 3 -

3.2.4 Solid Color Primer ............................................................................................................. - 3 -

3.2.5 Burst and Translucent finishes .......................................................................................... - 4 -

3.2.6 Clear Top coats .................................................................................................................. - 4 -

3.2.7 Buff finish .......................................................................................................................... - 4 -

3 Finish Before starting the finish make sure all holes are drilled for any remaining hardware (pickguard, jack

plate, strap pins etc). This section will cover the application of several finish types, including;

1. Solid color

2. Pigmented translucent, gel stain or alcohol dye

3. Penetrating stain or water based dye

The guitar body was sanded at the factory and coated with one coat of sand and sealer. To get a good

finish, the body should be sanded with a series of sandpaper grits up to #320 grit. Apply a solid color

finish, a pigmented translucent finish (Bursts, toners, Blonde, Butterscotch Blonde etc), a gel based stain

or an alcohol based dye finish over the sanding sealer. If you plan on using a penetrating stain or water

based dye, the sanding sealer must be removed.

How you proceed will depend on the finish you would like on your guitar.

The following paragraphs outline several finishing processes, starting with the sequence for a finish type

(paragraph 3.1) followed by detailed explanation of each sequence step (paragraph 3.2).



Caution: if you remove the nut/string tie down from the headstock in preparation for finishing the neck,

tape/cover the mounting area on the neck as to avoid material build-up that might influence the tuning

of your guitar.

3.1 Finish Application Steps

3.1.1 Solid Color finish:

1. Sand the body and neck

2. Apply grain filler if desired.

3. Apply 2 coats of sand and sealer

4. Sand to 320 grit

5. Apply primer

6. Sand the primer

7. Apply color coats

8. Apply clear top coats

9. Buff finish

3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish:

1. Sand the body and neck



4. Sand to 320 grit

5. Apply stain or dye


7. Buff finish

3.1.3 Penetrating Stain or water based dye finish:

1. Sand the body and neck to bare wood


3. Apply stain or dye


5. Sand to 320 grit


7. Buff finish

3.2 Explanation of Sequence Steps:

3.2.1 Sanding the Body and Neck

1. Wear a NIOSH-approved respirator and ANSI-approved safety glasses when sanding wood!

2. Before starting the finish on the neck mask off the surface of the fingerboard.

TIP… re-open any of the screw holes in the body. Use a toothpick or small drill held between

your fingers to clean out any filler in the holes.



3. Use a flexible sanding block with #150 grit aluminum-oxide sanding paper to sand the guitar

body until there is a consistent scratch pattern on the entire surface. Note: DO NOT round over

the neck pocket or the body cavities. When hand sanding, always sand in the same direction as

the wood grain.

4. Re-sand the entire guitar body and neck with #220 grit sanding paper and lightly round over the

outside edges of the body.

5. Wipe the guitar body and neck with a damp cloth to “raise" the wood grain.

6. Wait until the wood is dry and re-sand with #220 grit sandpaper to sand the “raised" grain

smooth.

(Note: On a maple fingerboard you can apply a clear finish to the entire neck and fingerboard. Apply

several coats and remove buildup on the frets between coats. An easy way to remove the finish buildup

on the frets is to take a nail and file a half round slot in the head about the same size as the frets. You

can then use this to easily scrape any finish build up.

If the neck has a Rosewood or Ebony fingerboard, be sure to tape off the fingerboard before applying

the finish. Behlen’s Fingerboard Oil is a great product for your fingerboard.)

3.2.2 Appling Grain Filler

Grain filler will fill in the grain and create flat surface. This is essential if you are trying to get a high gloss

finish. Oil based grain filler is recommended. We recommend using Behlen PORE-O-PAC grain filler. For

most finishes use natural colored filler. The dyes used in darker fillers may over time find their way

through the color coat.

Apply the filler by wiping across the grain. You can use a course cloth or your fingers to wipe the grain in.

After it has dried about ten to twenty minutes the excess can be removed with a cloth dampened with

mineral sprits. After about an hour repeat the process and let dry overnight. If you have removed most

of the excess with mineral spirits the remaining filler on the field of the wood can be sanded off (use

#220 again) in a few minutes. It is also a good idea at this time to reopen any of the screw holes in the

body. Use a toothpick or small drill held between your fingers to clean out any filler in the holes. The

body is now ready for a sand and sealer coating.

3.2.3 Applying Sanding Sealer

Sand and sealer is used to give the final coat a level base. It is also helpful in filling scratches which are

too deep to sand out. We recommend using Behlen Vinyl Sealer. This comes in aerosol cans and can

easily be sprayed on.

3.2.4 Solid Color Primer

The last step before applying the color coats is to apply a white primer coat. We recommend using Ohio

Valley Nitro Primer. The white background will also let you apply an opaque color coat with less paint.

Spray on two coats. When dry you may notice that the surface feels rough. Sand off the roughness with

#320 dry and respray. Sand again. If the surface now appears smooth and all grain is opaqued you are

ready for the color coat.



3.2.5 Burst and Translucent finishes

Bursts and Translucent finishes can be applied using aerosol cans of lacquer toner. Ohio Valley Nitro

and Behlen have a full line of Nitrocellulose Lacquer Toners to achieve these finishes.

3.2.6 Clear Top coats

Apply several thin coats of the finish, following the manufacturer's instructions. Multiple thin coats

usually produce a better quality finish than one heavy coat. Dry sand the entire body with #400 grit wet

dry sandpaper after at least three coats of finish have been applied. DO NOT sand through the finish, be

careful on the edges. Use a tack cloth to remove sanding residue. Apply more finish, sanding between

coats, until the finish is the desired thickness.

3.2.7 Buff finish

When the final coat has dried at least a week, preferably a month, remove the masking. Wet sand the

finish using #600 grit wet/dry sandpaper with a sanding block, followed with #1000 grit wet/dry

sandpaper. Use a clean, absorbent rag to remove excess water. Let the guitar dry completely, then use

a tack cloth to remove all residue. Buff the finish by hand or with a buffer, starting with a medium polish

and working up to a high gloss polish.

Note: If you use a buffing machine, be careful to avoid going through the finish, especially on the edges.



Section 4 Contents

4 Assembly ........................................................................................................................................... - 1 -

4.1 Installing the tuners .................................................................................................................. - 1 -

4.2 Neck Installation ....................................................................................................................... - 1 -

4.3 Installing the Strap Pins ............................................................................................................. - 1 -

4.4 Installing the Floyd Rose Tremolo ............................................................................................. - 2 -

4.5 Install the Pickup ....................................................................................................................... - 2 -

4.6 Prep the for the Output Jack, Volume control & wiring ........................................................... - 3 -

4.6.1 Wire color coding/prep ..................................................................................................... - 3 -

4.6.2 Soldering the Components ............................................................................................... - 4 -

4.6.3 Final wiring – Volume Control ........................................................................................... - 4 -

4.7 Install the Strings....................................................................................................................... - 4 -

4.8 Tremolo Claw Adjustment ........................................................................................................ - 6 -

4 Assembly After your finish has been applied and thoroughly dried, we can now assemble your guitar. In this

section we will permanently install all of the components and solder the wiring for the pickup/volume

control.

4.1 Installing the tuners Each tuner consists of the tuner, washer, and a threaded bushing. The tuners are attached to the

headstock with 3/8” wood screws (refer to Section 2.7).

4. Place the six tuners into the holes on the back of the headstock;

5. Slide a washer over the tuner shaft and secure the threaded bushing onto the tuner – do not

tighten yet;

6. Secure the machine heads to the guitar headstock with the supplied screws - tighten the

threaded bushings. Remove the protective film if necessary.

4.2 Neck Installation 1. Insert the neck into the neck pocket, aligning the mounting holes in the neck and body;

2. Fasten the Neck & Body with 4 x 1 3/8” screws – do not over tighten.

4.3 Installing the Strap Pins Secure each strap pins (2) in the pre-drilled holes with the supplied screws (2ea, 1”).

TIP… use a blanket or large towel on your work area to protect your guitars’ finish



4.4 Installing the Floyd Rose Tremolo Unlike hard mounted brides, the Floyd Rose style utilizes a

floating bridge base that allows the tremolo to pivot

forward and backward. The floating bridge is balanced

(positioned) between the tension of the strings and the

tension of the springs in the back pocket in the body of

your guitar. This type of system requires several iterations

of the string & spring tension adjustment to optimize your

style of playing.

1. Install the Trem claw in the front of the bottom

Pocket (Fig 4.4-1), ensuring it is centered in the

Pocket, so that about ½ of the screw threads are

exposed. This allows you to adjust the tension of

the springs.

2. Insert the Bridge mount adjustment screws into the

inserts – final height adjustment will be made when

the strings are installed.

3. Prior to installing the trem block, set the Fine

Adjustment screws to mid-range (Fig. 4.4-2) and

loosen the string locking bolts so they can be hand

tightened. Should the saddle blocks (small black

inserts behind the string saddle) fall out, ensure

that the indention faces the locking bolt when you

replace them.

4. Insert the trem block in the front of the Body and attach the springs using pliers to stretch the

springs into position. Use the center and each end tab on the claw to attach the 3 springs (Fig

4.4-3). [ Caution: if you lose grip of a spring it can fly

and cause injury as well as damage to the paint on

the body] Tighten the screws on the spring claw so

there is a little play in the block. The block still

needs to be able to move if you plan on using a

whammy bar.

4.5 Install the Pickup Install the Pickup (item #11 on material list) as follows:

1. Run the shielded Pickup wire through the tunnel

(Fig. 2.3) to the Volume pocket;

2. Carefully secure the to the Body with supplied ¾” screws;

Figure 4.4-3 Tremolo Claw Installation

Figure 4.4-2 Bridge Adjustments

Installation

Figure 4.4-1 Tremolo Claw Installation



4.6 Prep the for the Output Jack, Volume control & wiring In this section, you will identify the components that need to be soldered, trim the wiring and pre-wire

components to be installed later. As soldering to mounted components can be difficult, pre-wiring will

save you time.

4.6.1 Wire color coding/prep

Several suppliers are used, possibly resulting in different wire colors. Identification of colors and cross

referencing their function to the colors in the instructions (Figure 4.6.2-1) will assist in the assembly.

The kit comes with a ribbon wire (item 2 on the material list) or possibly individual wires:

1. Ribbon wire (black & red), black;

2. If your kit contains this colored ribbon wire, skip to 4;

3. Using Table 4.6.1, cross reference supplied wire color codes with colors used in these

instructions;

Table 4.6.1 Wire Color Code Cross Reference

Instruction Color Code

(Figure 4.6.2-1)

Your color code Function

Black & Red

Black

Red

…………………………….

…………………………….

Audio output

Ground

Signal

Black Black ……………………………. Tremolo & Volume pot ground

4. Separate the ribbon wire into an individual wires: black & red;

5. Cut approximately 2” from one of the black wires’

6. Strip the insulation back about 3/8” and tin all wires.

Figure 4.6.2-1 Lunatic Wiring Diagram



4.6.2 Soldering the Components

Pre-wiring several of the components will ease the final assembly and reduce the opportunity of

scratching your guitar (refer to the color translation table as required).

1. Secure the Volume control for soldering;

2. Solder the one end of the long black wires to the case of the Volume control;

3. Solder one end of the 2” black wire to the case of the Volume control and the other end to pin 1

of the Volume control (reference Fig. 4.6.2-1);

4. Solder the Red wire (output signal wire) to pin 2 of

the Volume control;

5. Solder the Pickup signal wire to pin 3 of the

Volume pot, and the braided shield to the case of

the Volume pot.

4.6.3 Final wiring – Volume Control

After running the Trem claw ground wire (black) and the

Audio signal wires (black/red) through the appropriate

tunnel (Fig. 4.6.3-1):

1. Carefully insert and secure the Volume control in

the circular pocket;

2. Solder the Output Jack to the black/red wires (Fig.

4.6.3-2): secure to the Body with 2 supplied

screws;

3. Solder the ground wire (black) to the tab on the

Trem claw;

4. Check to ensure the integrity of all of the solder

joints;

5. Install Volume knob & round access cover.

4.7 Install the Strings Like most projects, there often several tricks that will make the assembly easier and your guitar better.

Properly stringing your guitar is just one of those tricks. Please

review the following videos:

“TECH TIP: Restringing your Floyd Rose Guitar”: this

reminder… remove

the protective film from the back

covers, tuners & pickup

Figure 4.6.3-1 Body Wiring Tunnels

Figure 4.6.3-2 Output Jack Wiring

Tip… a small block of wood with a ¼” hole makes a stable platform to wire the Volume control



video deals with replacing the strings on a Floyd Rose Guitar but includes tricks that can be used for your

initial string installation.

https://www.youtube.com/watch?v=zEH3Ey76yb4&nohtml5=False

“Framus Tutorial: Setup of a Guitar with a Floyd Rose Tremolo”: this video also covers the replacement

of the strings as well as additional setup procedures you will need for section

5.

https://www.youtube.com/watch?v=YN7qF6JLoIc

Additional resources are available on as well as the internet. Although these

videos address restringing a guitar, the principles and techniques will help

you string your guitar – as well as provide a visual for stringing your guitar.

1. At the headstock, remove the 3 string lock blocks

from the nut using the 3mm Allen wrench and

align the tuners so that the hole is parallel to the

tuner shaft;

2. While holding the bridge assembly by the string

locking bolts, use the 3mm Allen wrench to

adjust the initial height of the bridge base so that

it is approximately 1/8” above the Body. Ensure

that the base notches are in the collared head of

the adjustment screw (Fig. 4.7-1);

3. Carefully uncoil each of the strings (6), ensuring

that the stings do not have a kink;

4. Select the low E string (largest diameter string) and remove the “string ball”, cutting the string

approximately 1” from the ball. Place the string between the low E saddle and the retaining

block, then tighten the associated string locking bolt with the 3 mm Allen wrench. Bend the

string down against the saddle with your finger to form a 90 degree bend;

5. Adjust the hole in the first tuner to be perpendicular to the neck;

6. Run the string upward through the hole in the tuner till snug on the neck and nut slot; gently

pull the string backward for a length of about 2 frets (check the video);

7. Run the string forward (toward the end of the headstock) wrapping the around the tuner and

under the sting; bend over the string (toward the end of the headstock);

8. Tighten the string down with the tuner; when the string is snug against the 1st slot in the nut,

trim the excess string;

9. Repeat steps 4-8 using the next smaller diameter string & the tuner;

10. Replace the nut locking blocks, but do not tighten;

11. Install the Tremolo arm (item #6 on the material list) on the Bridge. Offset the arm end by

approximately 2” (or at your preferred offset) from the high E string.

Figure 4.7-1 Tremolo String Installation

Tip… Put a shim

or block between the string locking bolts and the guitar

body. This will help hold the Bridge in place.

https://www.youtube.com/watch?v=zEH3Ey76yb4&nohtml5=False




Assembly of your Guitar is now complete – let’s

set it up!!

4.8 Tremolo Claw Adjustment The overall objective of this adjustment is to use the Tuners & claw tension adjustment to have the

bridge base elevated 1/16”, parallel to the Body and the guitar close to tune.

1. Recheck the height of the Bridge base ensuring the base is 1/16” on both sides of the Bridge –

adjust if necessary.

2. Tune the low E string with the tuner – check base and Body for being parallel. Tighten claw to

return to parallel if necessary. Ensure equal adjustment of both screws so claw remains parallel

to Tremolo block.

3. Repeat 1&2 on remaining strings.

4. Recheck tuning on all strings – repeat 1, 2 & 3 as necessary.

5. Install the Tremolo cover over the Tremolo pocket using supplied 3/8” screws.

Section 5 – Initial Setup


Section 5 Contents:

5 Initial setup ....................................................................................................................................... - 1 -

5.1 Adjust the Guitar Neck: Truss Rod ............................................................................................ - 2 -

5.1.1 Check the Neck .................................................................................................................. - 2 -

5.1.2 Adjusting the Truss Rod .................................................................................................... - 2 -

5.2 String Lubrication ...................................................................................................................... - 2 -

5.3 Re-check the Bridge Alignment ................................................................................................. - 3 -

5.4 Adjusting the Action (string height) .......................................................................................... - 3 -

5.5 Pickup Height (Figure 5.4) ......................................................................................................... - 4 -

5.6 Intonation (Figure 5.6) .............................................................................................................. - 4 -

5.7 …Other Hints ............................................................................................................................. - 5 -

5 Initial setup In this section, we will address the initial setup for:

1. Adjusting the Neck (Truss Rod);

2. Adjusting the String Action (string height);

3. Adjusting the Pickup heights;

4. Adjusting the Intonation.

These adjustments will provide preliminary settings from which you can fine tune the sounds to your

individual playing style. As with previous sections, references are included for visualization

and additional clarification of specific adjustments.

reference…check out the following references that can be helpful in tuning your

guitar:

tone generator for tuning: http://www.get-tuned.com/online_guitar_tuner.php &

http://www.guitarforbeginners.com/onlinetuner.html

downloadable “musical instrument tuner” from PerfectPitch (http://www.nch.com.au/tuner/) that

will allow visualization of string adjustments

In addition, check out this link for additional insights on setting up your guitar:

“How to Set up a Floyd Rose Bridge -- AND keep it in Tune”

http://www.guitarrepairbench.com/electric-guitar-repairs/floydrose_tremolo_setup.html

http://www.get-tuned.com/online_guitar_tuner.php

http://www.guitarforbeginners.com/onlinetuner.html

http://www.nch.com.au/tuner/

http://www.guitarrepairbench.com/electric-guitar-repairs/floydrose_tremolo_setup.html



Ensure that the locks (3 each) are removed from the nut then tune the guitar.

5.1 Adjust the Guitar Neck: Truss Rod The first major procedure in the setup is adjusting the neck relief. Neck relief simply refers to how much

the neck bows. The degree of bowing in the neck is a matter of personal preference and is correlated to

your playing style.

5.1.1 Check the Neck

Get a ruler or straightedge that is at least as

long as the neck, but not so long that it reaches

all the way from the nut to the saddles. If you

can’t get one between these lengths, and are

willing to sacrifice a ruler, get one that’s too

long and cut it to length. Alternatively, you can

just cut a little out of one edge so that you can still make full use of the other edge of the ruler. Now lay

the edge of the ruler along the frets (don’t rest it on top of the nut, saddles, or pickups).

Using a feeler gauge or high resolution metal ruler, measure the string height (the gap between the

ruler/string and the top of the fret) at about the 8th fret. The string height should be approximately

0.012” - simply slide the feeler gauge into the gap to see if it is too big/small.

5.1.2 Adjusting the Truss Rod

Tightening the truss rod adjustment bolt will cause the neck to warp backward (too much and the

strings will buzz on the frets), and loosening it will cause it to bow forward (giving more relief.).

CAUTION: If you find that the truss rod is very difficult to turn, then stop. It may be that there is a

problem with the neck or the truss rod and you

may damage the guitar by forcing it.

Sight down the edge of the fingerboard from

behind the headstock, looking toward the body

of the guitar.

1. If the neck is too concave (action too

high), use the 4mm Allen wrench to turn the truss rod nut clockwise to remove excess relief

(only adjust ¼ turn at a time);

2. If the neck is too convex (strings too close to the fingerboard), turn the truss rod nut counter-

clockwise to allow the string tension to pull more relief into the neck;

3. Check the tuning, then re-check the gap with the feeler gauge and re-adjust as needed.

4. Replace the Truss access cover.

5.2 String Lubrication Lubricate the contact points of a string's travel to ensure tuning stability and reduce string breakage.

Lubricate string/saddle contact points on the nut and bridge with a light machine oil (…such as 3-in-1 oil

reference: …check out the following

for adjusting the Truss rod as well as other

setup adjustments:


TIP… do the neck adjustment in a series of

intermediate steps and re-tune your guitar before each

step – different tension on the strings changes the

adjustment of the neck. Ensure the nut locks are not

tightened for each adjustment




Fig 5.4 Action Adjustment

because it contains anti-rust and anti-corrosive properties) every time you change

strings. Use a Q-tip with oil rather than straight from the can.

5.3 Re-check the Bridge Alignment As part of the Assembly section, the height and floating position of the Bridge were set up. In this step

will recheck the Bridge and adjust if necessary.

1. Tune the guitar to pitch (…again)

2. Check the angle of the Bridge base relative to the Body: is it tilting toward the Body or lifting up

from the Body?

3. If the Bridge Base is parallel to the Body and is approximately 1/8” above the Body, continue to

Section 5.4;

4. Remove the cover from the claw pocket in the back of the Body;

5. Adjust the Bridge mounting screws to the 1/16” height;

6. Adjust the screws in small increments to lower the Bridge (tighten), or to raise the Bridge

(loosen). Adjust the screws equally;

7. Retune the guitar and check again – repeating steps 5-7;

8. Replace claw pocket cover.

5.4 Adjusting the Action (string height) This will adjust the height of the strings over the 12th fret. Minor adjustments are made by raising or

lowering the bridge which was previously set to 1/16” above the Body. As this is a matter of personal

preference, this initial adjustment will give a place to start. There should be a gradual increase in height

from the first string to the sixth string.

Adjusting saddle height is very easy on the

Lunatic guitar. Since the bridge can only be

adjusted at each end, there is no need to adjust

each saddle individually.

1. Check and, if necessary, adjust the low

(thick) E string height at the 12th fret to

2/64”. Do this by adjusting the height of

the bridge at the thick E string end (Fig.

5.4). This is done by rotating the Bridge

insert adjustment counter-clockwise to

raise the bridge or clockwise to lower it.

Adjust the height until string doesn’t buzz on any fret from being too low, but low enough that

you can play up and down the neck easily. There’s usually a sweet spot where you can just start

to detect some buzzing and you can leave it just a tiny bit higher than that. Be careful if you use

a tool as it is easy to slip and damage the finish on your guitar.

2. Now do the exact same procedure for the high (thin) E string using the other adjustment screw

to 3/64th over the 12th fret.



Fig 5.4 Pickup Height Measurement

Table 5.5

Pickup Height Guide

1st

String 6th

String

Pickup 2/64” 3/64”

Table 5.4 Pickup Height

Fig 5.6 Intonation Adjustment

3. Play the guitar a little bit to see if any of the other strings are buzzing. If, say, the

A string is still buzzing, then raise up the end of the bridge nearest to that string a little bit.

5.5 Pickup Height (Figure 5.4) The pickup is adjustable on the bass and treble sides. Finding the

best combination of tone and volume will require some

experimentation.

1 Bridge pickup:

1.1 Press the 1st string onto the last fret and hold;

1.2 Using a machinist ruler, measure the distance from

the top of the pole to the bottom of the 1st string –

note bass measurement;

1.3 Repeat #1.1 & #1.2 on the 6th string – note the treble

measurement;

Using Table 5.5 as a reference, adjust the height of the pickups by turning the adjustment screws for the

bridge, & neck pickups – recheck string heights after each adjustment.

5.6 Intonation (Figure 5.6) Adjustments should be made after all of the above have been accomplished.

1. Set the pickup selector switch in the middle position.

2. Turn the volume & tone controls to maximum.

3. Check tuning. Check each string at the 12th fret, harmonic to fretted note (make sure you are

depressing the string evenly to the fret, not the fingerboard).

4. If sharp, lengthen the string by adjusting the saddle back. If flat, shorten the string by moving

the saddle forward. Otherwise, go to step 5.7

a. Loosen the nut lock (on the

Headstock) for the specific string that

you are adjusting.

b. Then using the Tuner, remove the

tension on the Bridge saddle. Loosen

the saddle bolt with the supplied

2.5mm Allen wrench (Fig 5.6). Adjust

the saddle position in or out as

determined in step 4. (Additional



movement can be achieved by using the 2nd hole in the bridge to lock

down the saddle).

c. Tighten the saddle lock bolt, retune the string and tighten the nut lock.

d. Repeat step 3 until you are satisfied.

e. Tighten the nut lock bolt.

5.7 …Other Hints There are a few other things that you can do to optimize your tuning stability:

1. Each time you play your guitar, before you do your final tuning, play for a few minutes to allow

the strings to warm up. Metal expands when warm and contracts when cool. After you've

played a few riffs, you can then do your final tuning;

2. Wipe the strings, neck and bridge with a lint-free cloth after playing;

3. When transporting or storing your guitar, even for short periods, avoid leaving it anyplace you

wouldn't feel comfortable yourself.

Remember, guitars are tempered instruments! Re-tune, play and make further adjustments as needed.

We hope you have enjoyed building your guitar! If you have any questions along the way please email

us at [email protected].

Custom Shop Products:

Made in the U.S.A.

mailto:[email protected]

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